Ergonomics in the Textile and Apparel Industries

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Ergonomics in the Textile and Apparel Industries
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Introduction

• Challenges Facing the Industry Today
• Competition From Overseas Companies With Access
  to Inexpensive Labor
• Shortage of Available US Textile Workers
• Annual Turnover Rates Ranging From 30 to Over
  100

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Introduction

• Challenges Facing the Industry Today
• Learning Curves of Several Months to Attain
  Needed Skill Levels for Many Jobs
• Difficulty in Applying Modern Automation
  Technologies to Fabrics Processing

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Ergonomics

• Improving Ergonomic Conditions Can Improve
  Productivity and Safety - Enhance Competitiveness
• Reduce Worker Compensation Costs
• Provide More Reliable Workforce
• May Include Allocating High Risk Jobs to Machines
  Where Possible (They Will Be Going Overseas
  Anyway)

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Injuries and Illnesses Among Textile and Apparel
Workers

• 70 of Sewing Machine Operators Using Foot
  Controls Report Back Pain
• 35 Report Persistent Low Back Pain
• 25 Have Suffered a Compensable Cumulative Trauma
  Disorder (CTD)
• 81 of CTDs Were to the Wrist
• 14 of CTDs to the Elbow
• 5 of CTDs to the Shoulder

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Injuries and Illnesses Among Textile and Apparel
Workers

• 49 of Workers Experience Pain in the Neck
• Absenteeism Increases as Working Conditions
  Worsen
• Loss of Workers Due to Injuries or Turnover is
  Associated With Working Conditions

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Tasks Associated With Injuries and Illnesses

• Hand Sewing and Trimming are Stressful to All
  Upper Limbs
• Stitching Tasks are Associated With Pain in the
  Shoulders, Wrists, and Hands
• Ironing by Hand is Associated With Elbow Pain
• Garment Assembly Tasks are Associated With CTDs
  of the Hands and Wrists
• Foot Operated Sewing is Associated With Pain in
  the Back

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Static Postures and CTDs

• Analysis Reveals That 40 of Operators at Sewing
  Machines Stoop Forward gt 20o Throughout the
  Machine Cycle
• 60 Tilt Their Heads Forward gt 20o Throughout
  the Machine Cycle - Why?
• Visual Demands of the Work
• Geometry of the Work Station
• Inadequate Seating

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Postural Stress and Lighting

• Precise Stitching Tasks are Visually Demanding
• Thread and Fabric Often Offer Little or No Visual
  Contrast
• 36 of Operators Feel Lighting is Inadequate
• Surveys Found Light Levels at Less Than 60 of
  Recommended Levels
• Operators Lean Forward to See Their Work

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Seating

• Straight Backed Wooden or Metal Chairs are
  Typical in the Industry
• Chairs Often Lack Cushioning
• Chairs Often Lack Adjustable Back Rests
• Chairs Often Lack Height Adjustability
• Improved Seating is Readily Available

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PsychoSocial Considerations

• Psychomotor Demands are High (Speed, Accuracy,
  Coordination)
• Positive Attitudes Toward Work are Inversely
  Related to Increased Monotony and Fatigue
• Positive Attitudes Toward Work are Directly
  Related to Job Satisfaction

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Work Organization

• As Many as 100 of Piecework Operators in High
  Manipulation Jobs Have Symptoms of CTDs
• Workers in Piecework are 4 Times as Likely to
  Develop Severe Disabilities as Hourly Workers
• Workers in Piecework are 9 Times as Likely to
  Develop Arthritic and Osteoarticular Disorders as
  Hourly Workers
• As Duration of Employment in Piecework Increases,
  So Does Severe Disabilities

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Duration of Exposure

• Machine Operators Experience Cumulative Damage to
  the Neck and Shoulders Over Time
• Risk for Persistent Neck and Shoulder Pain
  Increases With Years of Employment as a Machine
  Operator
• Work for More Than Eight Years as Machine
  Operator Increases Risks For Neck and Shoulder
  Pain

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Solutions - A Comprehensive Ergonomics Program

• Training for Supervisors and Managers
• Awareness Training for Employees
• Job Analyses and Implementation of Controls
• Worker Involvement and Participation
• Medical Management
• Recommended by National Institute of Occupational
  Safety and Health (NIOSH)

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WorkStation Redesign - Sewing Machines

• 30 Fixed TableTop Height
• Point of Operation Between 4-7 Above TableTop
• Sewing Machine Tilted 11o Toward Operator
• For Jobs of Longer Duration Sewing - Bench
  Mounted Arm Rests
• Adjustable Chair
• Adjustable Foot Rest With Movable Machine Control

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Work Enhancements

• Foam Padded Edges to Sharp Table Edges
• Provide Cloth Upholstered Adjustable Chairs
• Angle Packing Boxes to Workers With Tilt
  Equipment
• Provide Anti-Fatigue Matting for Standing Workers
• Improved Lighting
• Require Rest Periods
• Job Rotations

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Automated Materials Handling

• Eliminates Heavy Lifting by Operators or Bundle
  Boys
• Uses Pre-Programmed Hanging Conveyor
• Moves Only One or a Few Work Pieces Per Hanger
• Computer Controlled - Movement Tracked by
  Bar-Coded Hangers and Series of Scanners
• Delivers Work to Queue Near Operator

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Automated Materials Handling

• Strong on Pre-Programmed Use But Weak on
  Flexibility (Short Term Changes, etc.)
• Technology is Rapidly Improving
• Future Models Will Direct More Work to the Queues
  of the Most Productive Workers and Less to Slower
  Workers or Beginners

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Modular Manufacturing Concept

• Conventional Textile/Apparel Industries Use the
  Progressive Bundle System - Each Operator is
  Assigned to a Single Operation
• In Modular Mfg. a Complete Garment is Produced in
  a Modular Cell
• Cells May Have 10 Operators and 20 Machines
• Operators Are Not Assigned to a Single Operation
  But Move Between Workstations

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Modular Manufacturing Concept

• Teams of Operators are Responsible for Work
  Planning and Management, Product Quality, etc.
• Employees are Empowered - Boosts Morale
• A Variety of Motions are Used by Each Operator -
  Reduces Risk for CTDs and Relieves Static
  Postures
• Can Be Reconfigured Rapidly, Providing Great
  Flexibility

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Modular Manufacturing

• Significantly Reduced Absenteeism
• Necessitates Better Ergonomic Designs of
  Workstations to Accommodate Different Operators
• Many Operations Converted to Standing
  Workstations Instead of Seated Workstations
• Employees Paid on a Group Incentive System

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Additional Resources

• American Textile Manufacturers Institute (ATMI)
  Washington DC
• ATMI Quest for Best in Safety and Health Program
• Must Have Comprehensive Program to Join
• Must be Willing to Interact With Other Members
  Companies
• Nearly Half of ATMI Member Companies Participate

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Additional Resources

• National Institute for Occupational Safety and
  Health (NIOSH)
• 800-35-NIOSH
• NIOSH Publication Elements of Ergonomics
  Programs, January 1997

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Questions and Answers
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This program developed by David Mahone, CNA
Insurance Companies, Chicago IL

• Corporate Underwriting Center